Closure having band with internal thread formed by impression

0001This is a divisional of application Ser. No. 10/079,769 filed Feb. 21, 2002, now U.S. Pat. No. 7,134,565 which claims the benefit of U.S. Provisional Application No. 60/270,757 filed Feb. 22, 2001, which is incorporated by reference herein.

BACKGROUND OF THE INVENTION

0002The present invention relates to container closures, and more particularly to closures having threads formed thereon and related methods.

0003Conventional injection molded, plastic closures often include a circular top member, a cylindrical skirt that depends downwardly from the top member, threads formed on the interior of the skirt, and a tamper evident band formed on a lower rim of the skirt. Typically, such closures are molded in a one-step process such that the top member, skirt, and threads are integrally formed. Closures having threads integrally molded as part of the skirt typically require a rotary capper operation to twist the threaded closure onto matching threads on the container finish. A conventional rotary capper process is relatively slow and requires expensive machinery compared with commercial, high-speed, conventional press-on or in-line capper technology.

0004Conventional composite closures typically include a metal panel for covering and sealing to a container rim and a threaded plastic band for coupling to mating container threads. U.S. Pat. No. 5,685,443 discloses embodiments of such a band that may be pressed-on and twisted-off.

0005Another type of conventional closure is formed of an integral metal top member and metal skirt. A particular type of metal skirt is formed with a smooth, cylindrical sidewall. A liquid or flowable material, such as plastisol, is subsequently applied to the skirt inner wall, usually by spraying while the closure is spinning. The plastisol, or like material, is formed on the skirt sidewall by a process that includes baking, curing, or a similar treatment step. U.S. Pat. No. 5,190,177 discloses a press-on, twist-off metal closure having a conventional lining into which threads are formed by the container thread, and requires a baking or curing step.

0006Further, the baking or curing process makes it difficult or infeasible to provide such a metal closure with an integrally formed, frangible tamper evident band of the type that depends from the bottom of the skirt and detaches upon removal of the closure from the container. Although the metal top member may include a button-type tamper evident feature, for hot-fill applications, it is often preferable to employ a frangible, tamper evident band. For example, the U.S. Pat. No. 5,190,177 discloses that the tamper evident band is formed by a separate security ring that is fitted into an annular shoulder formed on the peripheral skirt.

0007Thus, there is a need for improved closures, and techniques for forming closures.

SUMMARY OF THE INVENTION

0008The present invention relates to container closures, methods and molding systems for molding closures, and methods for combining containers and closures to form packages, including but not limited to hermetically sealed packages. According to an aspect of the present invention, a closure is provided that mates with a container having a finish that includes threads formed thereon. The closure comprises a flange; a skirt depending downwardly from a periphery of the flange; and a deformable element disposed on an interior surface of the skirt that is deformable by the container threads to impress a closure thread into the element. Thus, the closure may be applied with straight-line capping equipment. The closure may include at least one passage extending through the flange or skirt.

0009The closure may be a composite closure such that the flange is disposed over an insert disk. The insert disk may form an annular channel in which a sealant is disposed to enhance the seal between the insert disk and the container rim. Further, the present invention enables the insert disk to be floatable with respect to the flange and/or skirt. The present invention encompasses any channel configuration, or alternatively, the flange may be a continuous disk. The deformable element is spaced apart from the insert disk, and/or from the flange.

0010According to another aspect of the present invention, a method for molding a closure comprises injecting a first material into a first mold cavity so as to form a closure flange and skirt, and subsequently injecting a second material into a second cavity that is coupled to the first cavity. According to yet another aspect of the present invention, at least one passage may be formed through the wall of the closure, such as from the exterior surface of the flange or skirt of the closure to an interior surface such that the second material may flow through the passage during injection of the second material.

0011A molding system for making closures provided by the present invention may include a first closure cavity surface and a first closure core surface defining a first closure cavity therebetween. The first closure cavity preferably includes a flange portion and a skirt portion for forming a closure having a corresponding flange and a skirt, and a second closure core and an interior wall of the skirt defining a second closure cavity therebetween for forming a deformable element disposed on the interior surface of the skirt. The first and second cavities may be formed within the same apparatus or in separate molding apparatus, as will be clear to persons generally familiar with conventional sequential injection molding.

0012According to another aspect of the present invention, a pin may extend into a portion of the first closure cavity from the first closure cavity surface to the first closure core for defining a passage within the first material through the flange and the skirt. Material may be injected through the passage into the second closure cavity.

0013According to another aspect of the present invention, methods for closing a package comprising a closure of the present invention and a container having a finish with a thread thereon have been provided. One method includes providing a container having a finish with threads disposed thereon, providing a closure having a deformable element disposed on an interior surface of the closure skirt, and urging the closure onto the container finish such that the element is deformed by the container thread to impress threads therein.

BRIEF DESCRIPTION OF THE DRAWINGS

0014<figref idref="DRAWINGS">FIG. 1</figref> is a sectional view of a portion of a container and a closure according to a first embodiment of an aspect of the present invention illustrating the deformable element in an undeformed state;

0015<figref idref="DRAWINGS">FIG. 2</figref> is a sectional view of a portion of a container and a closure according to a second embodiment of an aspect of the present invention illustrating the deformable element in an undeformed state;

0016<figref idref="DRAWINGS">FIG. 3</figref> illustrates the first embodiment shown in <figref idref="DRAWINGS">FIG. 1</figref> including a tamper evident band illustrating the deformable element in an undeformed state;

0017<figref idref="DRAWINGS">FIG. 4</figref> illustrates the first embodiment shown in <figref idref="DRAWINGS">FIG. 1</figref> including another tamper evident band;

0018<figref idref="DRAWINGS">FIG. 5A</figref> is a sectional view of a portion of a closure illustrating another aspect of the present invention;

0019<figref idref="DRAWINGS">FIG. 5B</figref> is a sectional view of a portion of the closure taken through lines <b>5</b>B-<b>5</b>B in <figref idref="DRAWINGS">FIG. 5A</figref> illustrating an exemplary configuration of the deformable element;

0020<figref idref="DRAWINGS">FIG. 6</figref> is a sectional view of a portion of the closure shown in <figref idref="DRAWINGS">FIG. 1</figref>;

0021<figref idref="DRAWINGS">FIG. 7</figref> is a sectional view of the embodiment of the container and closure shown in <figref idref="DRAWINGS">FIG. 3</figref> illustrating the deformable element in a deformed state with closure threads formed therein;

0022<figref idref="DRAWINGS">FIG. 8</figref> is a sectional view of a first portion of a molding system according to an aspect of the present invention;

0023<figref idref="DRAWINGS">FIG. 9</figref> is a sectional view of the portion the molding system of <figref idref="DRAWINGS">FIG. 8</figref> illustrating a portion of a closure formed therein;

0024<figref idref="DRAWINGS">FIG. 10</figref> is a sectional view of a second portion of the molding system of <figref idref="DRAWINGS">FIG. 8</figref> according to an aspect of the present invention;

0025<figref idref="DRAWINGS">FIG. 11</figref> is a sectional view of the portion of the molding system shown in <figref idref="DRAWINGS">FIG. 10</figref> illustrating the deformable element formed therein;

0026<figref idref="DRAWINGS">FIG. 12</figref> is a sectional view of a first portion of another molding system according to another aspect of the present invention; and

0027<figref idref="DRAWINGS">FIG. 13</figref> is a sectional view of a second portion of the molding system of <figref idref="DRAWINGS">FIG. 12</figref> according to an aspect of the present invention.

PREFERRED EMBODIMENTS OF THE PRESENT INVENTION

0028According to aspects of the present invention, each of <figref idref="DRAWINGS">FIGS. 1 through 4</figref> illustrates an embodiment of a container package <b>9</b><i>a </i>through <b>9</b><i>d</i>, respectively, each of which includes a container and a closure. Preferably the containers are formed of a glass or a plastic that is suitable for vacuum-creating filling processes, as will be understood by persons familiar with commercial filling technology. The present invention is not limited thereto, but rather encompasses any container and/or closures formed of any material and may be employed with any configuration of containers and closures, regardless of the manner of their use.

0029The container packages illustrated in <figref idref="DRAWINGS">FIGS. 1 through 4</figref> each include a closure, as described more fully below, and a container <b>12</b>, which includes a finish <b>14</b> having threads <b>16</b> formed on an exterior thereof. Finish <b>14</b> forms a rim <b>18</b>.

0030As shown in <figref idref="DRAWINGS">FIG. 1</figref> and according to a first embodiment of an aspect of the present invention, a closure <b>10</b><i>a </i>includes a flange <b>23</b><i>a</i>, a skirt <b>24</b>, an insert disk <b>25</b>, and a deformable element <b>26</b>. Skirt member <b>24</b> is substantially cylindrical and includes an interior surface <b>28</b>, an opposing exterior surface <b>30</b>, and a rim <b>32</b> formed at a bottom surface defined by interior surface <b>28</b> and exterior surface <b>30</b>. A substantially annular retaining member <b>8</b> protrudes inwardly from interior surface <b>28</b>. Flange <b>23</b><i>a </i>extends radially inwardly from an upper portion of skirt <b>24</b> and defines an opening <b>21</b> therein. Closure <b>10</b><i>a </i>also includes a gate <b>48</b>, as described more fully below.

0031Flange <b>23</b><i>a </i>and skirt <b>24</b> preferably are formed by injection molding a plastic material to form an integral, single piece. Any plastic may be employed for forming flange <b>23</b><i>a </i>and skirt <b>24</b>, such as for example a polyolefin, including, but not limited to, high-density polyethylene and polypropylene. U.S. Pat. No. 5,346,082, entitled “Composite Closure With Sealing Force Indicating Means And Ratchet Operated Tamper Indicating Band,” which is assigned to the assignee of the present invention and incorporated herein by reference in its entirety, discloses a composite closure having a skirt, flange, and insert disk.

0032Insert disk <b>25</b> is disposed between the underside of flange <b>23</b><i>a </i>and a retaining member <b>8</b> that protrudes inwardly from skirt <b>24</b>. Insert disk <b>25</b> may include an optional, central button-type tamper evident indicator <b>49</b> disposed at a center of disk <b>25</b>, an annular channel <b>52</b> that receives the container rim <b>18</b>, a sealant, such as plastisol <b>54</b> or like material or component, disposed in annular channel <b>52</b>, and abead or curl <b>56</b> disposed at an outer edge of disk <b>25</b>. Tamper indicating button <b>49</b> is shown in its up position in <figref idref="DRAWINGS">FIG. 1</figref>. Plastisol <b>54</b>, as illustrated in the Figures, preferably forms a seal against a top surface of container rim <b>18</b>, and seals against both an upper inside surface and an upper outside surface of container finish <b>12</b> proximate rim <b>18</b>. Such a three-way seal may accommodate dimensional irregularities or tolerance ranges of the respective parts, as well as maintaining a seal during thermal expansion and contraction during hot filling or retort operations. In most circumstances, including those in which disk <b>25</b> is formed of metal and flange <b>23</b><i>a </i>and skirt <b>24</b> are formed of a plastic, the parts have different coefficients of thermal expansion for which sealant <b>54</b> is beneficial.

0033After the capping and filling processes, the panel, which may (optionally) include button <b>49</b>, deflects to a down position upon cooling of the contents (not shown) and creation of vacuum conditions within container <b>12</b>. The down or vacuum button position is diagrammatically shown in dashed lines in <figref idref="DRAWINGS">FIG. 1</figref>.

0034Preferably, retaining member <b>8</b> is spaced apart from the underside of flange <b>23</b><i>a </i>such that insert disk <b>25</b>—that is, curl <b>56</b>—is floatable therebetween (while the closure <b>10</b><i>a </i>is, for example, unconnected from the container <b>12</b>). Insert disk <b>25</b> may be made by conventional means of metal, although other materials, including thermoplastic, are encompassed by the present invention. The present invention is not limited to the particular configuration of insert disk <b>25</b>, but rather encompasses any insert disk configuration, as well as closures lacking an insert disk, as explained more fully below. Other methods of making insert disk <b>25</b> may also be employed.

0035Retaining member <b>8</b> provides an upper boundary during the injection of the material forming deformable element <b>26</b>, as well as a providing a stop against which deformable element <b>26</b> may urge during capping. Thus, the material forming deformable element <b>26</b> may be kept spaced apart from rim <b>18</b> of the container during and subsequent to the capping process. For embodiments including a composite closure, such a spacing may be advantageous during the capping or opening process, or the like.

0036A first embodiment of deformable element <b>26</b> is shown in <figref idref="DRAWINGS">FIG. 1</figref> (as well as in <figref idref="DRAWINGS">FIGS. 2 through 4</figref>) in an undeformed, as-molded state. <figref idref="DRAWINGS">FIG. 6</figref> also illustrates deformable element <b>26</b> in an undeformed state prior to coupling with container <b>12</b>. In its undeformed state, inner surface <b>34</b> has a inner diameter D-AB that is less than an outer diameter D-CT of the container threads <b>16</b>. Deformable element <b>26</b> is formed on interior surface <b>28</b> of skirt <b>24</b> such that inside surface <b>34</b> of deformable element <b>26</b> (in its undeformed state) preferably is cylindrical (that is, flat in longitudinal cross section as shown in the Figures). In this regard, container <b>12</b> is shown in <figref idref="DRAWINGS">FIG. 1</figref> (as well as in <figref idref="DRAWINGS">FIGS. 2 through 4</figref>) in dashed lines to enable deformable element <b>26</b> to be shown in its undeformed state for clarity. The present invention also encompasses deformable element having inner surfaces that are irregular, conical, and of other configurations.

0037Thus, element <b>26</b> is formed of a material that is deformable and has a desirable compression set compared with that of the material that forms skirt <b>24</b>. Further element <b>26</b> preferably is formed of a material that is substantially incompressible, although the present invention encompasses materials of a wide range of compressibilities that are suitable for the required deformation. The term “incompressible” as employed herein refers to a material that maintains an approximately constant volume while a stress or force is applied to at least a portion thereof, and encompasses materials that temporarily compress and rebound.

0038Element <b>26</b> may be formed of any suitable material (encompassing incompressible materials and/or compressible materials), and it has been found to be helpful to describe some suitable materials by employing the parameters of hardness and compression set. The following is a nonexclusive list of suitable materials:

0039ADVANCED ELASTOMER SYSTEM (“AES”) TREFSIN Number 3271-65W308, Hardness: 65 (Shore “A”, nominal), Compression Set: 13% 22 hrs. @ 23° C. &amp; 49% 22 hrs. @ 100° C.;

0040TEKNOR APEX Number MP 2870M, Hardness: 70 (Shore “A”), Compression Set: 25% @ 23° C.;

0041AES VYRAM Number 9201-55, Hardness: 55 (Shore “A”), Compression Set: 25% 168 hrs. @ 23° C. &amp; 40% 168 hrs. @ 100° C.; and/or

0042AES VYRAM Number 9201-65, Hardness: 65 (Shore “A”), Compression Set: 28% 168 hrs. @ 23° C. &amp; 43% 168 hrs. @ 100° C.

0043The above values for hardness are according to ASTM D2240, and for compression set are according to ASTM D 395, Method B.

0044International Patent Application PCT/GB98/01467, which is assigned to the assignee of the present invention, discloses a press-on/twist-off closure having a single pro formed gasket into which both the threads and a seal between the closure and the container rim are formed. Such a configuration is generally commercially disadvantageous for use with composite closures, as well as with other closures employed with a hot-filling or retort process (or other process that subjects the container to internal vacuum pressures), or with closures for which it is desired to form a seal between the closure and the container rim by means other than the single, deformable gasket. The international application also includes a list of materials that may be suitable for use as deformable element <b>26</b> of the present invention in some circumstances. Table 1 from the international application is reproduced herein.

0045According to another embodiment of the present invention as shown in <figref idref="DRAWINGS">FIG. 2</figref>, a closure <b>10</b><i>b </i>includes substantially flat, circular top portion <b>23</b><i>b</i>, a cylindrical skirt <b>24</b> depending downwardly from an outer periphery of top portion <b>23</b><i>b</i>, and a deformable element <b>26</b>. A liner <b>22</b> may be disposed on the underside of flange <b>23</b><i>b</i>, as shown in <figref idref="DRAWINGS">FIG. 2</figref>. Liner <b>22</b> may be conventional, and/or may include an oxygen scavenging compound as will be understood by persons familiar with such technology. Flange <b>23</b><i>b </i>and skirt <b>24</b> preferably are integrally formed by injection molding, using thermoplastic materials—for example those materials comprising a polyolefin. Closure <b>10</b><i>b</i>, as shown in <figref idref="DRAWINGS">FIG. 2</figref>, does not have an insert disk, but rather flange <b>23</b><i>b </i>is continuous such that it covers the container opening, thereby forming a one-piece closure <b>10</b><i>b. </i>

0046Closures <b>10</b><i>a </i>and <b>10</b><i>b </i>are shown in <figref idref="DRAWINGS">FIGS. 1 and 2</figref> without tamper evident bands, although the present invention encompasses closures <b>10</b><i>a </i>and <b>10</b><i>b </i>having tamper evident bands. In this regard, as best shown in <figref idref="DRAWINGS">FIGS. 3 and 4</figref>, according to another aspect of the present invention, closures <b>10</b><i>c </i>and <b>10</b><i>d </i>illustrate closure <b>10</b><i>a </i>with the addition of a tamper evident band. Closures <b>10</b><i>c </i>and <b>10</b><i>d </i>are, thus, structurally similar to closure <b>10</b><i>a </i>except for tamper evident bands <b>36</b><i>a </i>and <b>36</b><i>b</i>. For convenience, only closure <b>10</b><i>a</i>, rather than both closures <b>10</b><i>a </i>and <b>10</b><i>b</i>, is shown herein having a tamper evident band. As will the clear to a person generally familiar with the configuration and design of conventional closure configuration and technology in light of the present disclosure, the present invention encompasses all types of closures, including closure <b>10</b><i>b</i>, having any type of tamper evident band (such as, for example, vented or unvented integrally formed with skirt <b>24</b> or mechanically joined, including conventional draining or wash-out features to enable liquid in the thread area to drain, etc.).

0047As shown in <figref idref="DRAWINGS">FIG. 3</figref>, closure <b>10</b><i>c </i>includes a tamper evident band <b>36</b><i>a </i>that is frangibly connected to lower rim <b>32</b> of skirt <b>24</b> at frangible connection <b>38</b><i>a</i>. Tamper evident band <b>36</b><i>a </i>includes a hinge portion <b>40</b> and a moveable band <b>42</b> coupled to hinge portion <b>40</b> opposite skirt rim <b>32</b>. Positions of band <b>42</b> are shown in dashed lines in <figref idref="DRAWINGS">FIG. 3</figref> to indicate its capability to pivot about hinge <b>40</b>. After the assembly of closure <b>10</b><i>c </i>onto container finish <b>14</b>, band <b>42</b> is disposed on an underside of a tamper evident bead <b>20</b>′ that protrudes from the outer sidewall of container finish <b>14</b>.

0048As shown in <figref idref="DRAWINGS">FIG. 4</figref>, closure <b>10</b><i>d </i>includes a tamper evident band <b>36</b><i>b </i>that is frangibly connected to the lower end of skirt rim <b>32</b> at a frangible connection <b>38</b><i>b</i>. Tamper evident band <b>36</b><i>b </i>includes a flange <b>44</b> that protrudes inwardly from an inner sidewall of tamper evident band <b>36</b><i>b </i>below frangible connection <b>38</b><i>b</i>. After the assembly of closure <b>10</b><i>d </i>onto container finish <b>14</b>, flange <b>44</b> is disposed on an underside of a tamper evident bead <b>20</b>″ that protrudes from the outer sidewall of container finish <b>14</b>.

0049Preferably, closures <b>10</b><i>c </i>and <b>10</b><i>d </i>are configured for sequential opening such that, during the opening process, first the friction force of the threads is overcome to initiate twisting, then tamper evident band <b>36</b><i>a </i>or <b>36</b><i>b </i>is ruptured, followed by opening of disk <b>25</b> by retaining member <b>8</b>, which urges upwardly against disk curl <b>56</b>.

0050According to another embodiment of the present invention, as shown in <figref idref="DRAWINGS">FIG. 5A</figref>, a closure <b>10</b> includes a flange <b>23</b><i>c</i>, a skirt <b>24</b>, a passage <b>7</b> extending through a portion of flange <b>23</b> and skirt <b>24</b>, and element <b>26</b> A portion of passage <b>7</b> is shown with cross hatching to illustrate that passage <b>7</b> serves as a runner for injecting material during the formation of element <b>26</b>. The material within passage <b>7</b> is referred to herein as a branch. Forming the runner internal to the closure (that is, as illustrated by passage <b>7</b>) diminishes costs and complexities involved with post-molding separation of closure and a runner, and the disposal/recycling of the runner. A corresponding mold and molding process associated with manufacturing a closure such as <b>10</b> will be discussed in more detail below.

0051Each of the <figref idref="DRAWINGS">FIGS. 1 through 6</figref> shows deformable element <b>26</b> in its undeformed, as-molded state to show the configuration of element <b>26</b> in its as-molded state and to illustrate the dimensional relationship between the as-molded state of element <b>26</b> and container threads <b>16</b>, and the like. Upon the molding of any of the closures <b>10</b>, <b>10</b><i>a</i>, <b>10</b><i>b</i>, <b>10</b><i>c</i>, and <b>10</b><i>d</i>, the closure may be installed onto container <b>12</b>. In this regard, <figref idref="DRAWINGS">FIG. 7</figref> shows the closure <b>10</b><i>c </i>coupled to container <b>12</b> to illustrate the deformation and forming of deformable element <b>26</b> and forming of closure threads <b>19</b> therein.

0052Element <b>26</b> may be circumferentially continuous or discontinuous. In this regard, a circumferentially continuous element would inhibit insect access to the portion of the closure <b>10</b>, <b>10</b><i>a</i>, <b>10</b><i>b</i>, <b>10</b><i>c</i>, and <b>10</b><i>d </i>above the threads. Alternatively, element <b>26</b> may be formed of discontinuous segments of deformable material, which are identified by reference numeral <b>34</b>′ in <figref idref="DRAWINGS">FIG. 5B</figref>. Discontinuous elements <b>34</b>′ form spaces <b>35</b> therebetween. The configuration illustrated in <figref idref="DRAWINGS">FIG. 5B</figref> may be beneficial in that spaces <b>35</b> may provide space into which a portion of elements <b>34</b>′ may be pushed during application. The present invention encompasses employing a continuous or discontinuous element <b>34</b>,<b>34</b>′, depending on the particular parameters of the application, as will be understood by persons familiar with such parameters. Further, any configuration of discontinuous elements <b>34</b>′ is contemplated.

0053In this regard, embodiment <b>10</b><i>c </i>of the closure is employed to describe a method of forming threads via impression or deformation according to another aspect of the present invention. Closure <b>10</b><i>c</i>, as shown in <figref idref="DRAWINGS">FIG. 3</figref> but omitting container <b>12</b>, may be molded according to the methods and apparatus described herein or by any other processes. Upon molding, deformable element <b>26</b> is undeformed—for example as shown in <figref idref="DRAWINGS">FIG. 6</figref>.

0054Closure <b>10</b><i>c </i>may be urged onto container <b>12</b>, which typically would include a food or beverage product disposed therein, directly downward along a longitudinal axis without twisting of closure <b>10</b><i>c </i>(that is, without twisting closure <b>10</b><i>c </i>about longitudinal axis A). Depending on the particular characteristics of the material of deformable element <b>26</b>, closure <b>10</b><i>c </i>may be urged downwardly such that the centerline CL is parallel or co-linear with a longitudinal axis (not explicitly identified in the figures) of the container finish <b>14</b> or such that centerline CL is angled thereto—that is, closure <b>10</b><i>c </i>may be angled relative to container <b>12</b> during application.

0055While deformable element <b>26</b> is urged onto the container finish <b>14</b>, the element <b>26</b> deforms sufficiently to extend into at least a portion of the area between the container threads <b>16</b>. Referring to <figref idref="DRAWINGS">FIGS. 1 and 7</figref>, as closure <b>10</b><i>c </i>(as molded) is urged downwardly toward container <b>12</b>, the uppermost portion of container thread <b>16</b> contacts lowermost portion of deformable element <b>26</b>. Because the container thread outer diameter D-CT is greater than the deformable element inner diameter D-AB, the material of deformable element <b>26</b> must deform as closure <b>10</b><i>c </i>is urged downwardly relative to container <b>12</b>.

0056Thus, the material of deformable element <b>26</b> preferably is deformable so as to deform over threads <b>16</b> in response to urging of closure <b>10</b><i>c </i>onto container finish <b>14</b>. Other attributes of the material of element <b>26</b> include a relatively low recovery rate to facilitate such deformation, a intermediate or relatively high compression set. The present invention, however, is not limited to materials having such attributes. Rather, the present invention encompasses employing any suitable material, as will be understood by persons familiar with deformable materials in light of the present disclosure, and reference should be made to the claims to ascertain the scope of materials.

0057The material of deformable element <b>26</b> thus deforms as the upper portion of thread <b>16</b> is further urged relative to the deformable element material. At least in part because the preferred deformable element material undergoes no or a small amount of volume change (at the end or long after the closure is coupled with the closure), the material of the deformable element deforms to substantially fill the spaces between the container threads <b>16</b>, thereby forming closure threads <b>34</b>′. Further, tamper evident band <b>36</b><i>a</i>, with band <b>42</b> in its upward or fishhook position <b>42</b>′, clears container threads <b>16</b>. Container rim <b>18</b> urges into plastisol in groove <b>54</b>, where applicable and as described above.

0058Thus, as illustrated in <figref idref="DRAWINGS">FIG. 7</figref>, the material of the deformable element upon deformation forms deformable element <b>26</b>′ having a surface <b>34</b>′ that has threads impressed therein so as to mate to container threads <b>16</b>. In this regard, a press-on or straight-line capper is used to urge closure <b>10</b><i>c </i>onto container <b>12</b> and the threads are formed as described herein. Although it is understood that employing a press-on or straight-line capper is preferred over employing a rotary capper for speed and economy, the present invention encompasses employing a rotary capper to twist closure <b>10</b><i>c </i>onto the container and thereby form surface threads <b>34</b>′. Further, the urging step encompasses pressing, rotating or both pressing and rotating the closure onto the container. During the urging step, the deformable element, disposed on the interior surface of the closure, deforms and container threads impress closure threads into the deformable element to form the closed package. To gain access to the container contents, a consumer may twist the closure off the container.

0059According to another aspect of the present invention, molding systems and methods for forming closures of the present invention will be described with respect to <figref idref="DRAWINGS">FIGS. 8 through 13</figref> and by again employing the configuration of closure <b>10</b><i>c </i>for illustration. As shown in <figref idref="DRAWINGS">FIGS. 8 and 9</figref>, a system <b>11</b><i>a </i>for molding at least a portion of the closures according to the present invention includes a molding cavity block <b>150</b><i>a</i>, a molding core <b>152</b>, a stripper <b>154</b>, and an ejector <b>156</b>. Cavity block <b>150</b><i>a </i>defines a sprue <b>164</b> therethrough. Sprue <b>164</b> includes a tip that forms gate <b>48</b>. <figref idref="DRAWINGS">FIGS. 1 through 6</figref> also employ reference numeral <b>48</b> to indicate the gate on the closure.

0060Cavity block <b>150</b><i>a </i>defines a cavity surface <b>151</b>, core <b>152</b> defines a mold core surface <b>153</b>, and stripper <b>154</b> defines a surface <b>155</b> such that surfaces <b>151</b>, <b>153</b>, and <b>155</b> define a cavity <b>159</b><i>a</i>. Cavity <b>159</b><i>a</i>, according to an aspect of the present invention, forms the shape of the closure <b>10</b><i>c </i>except for deformable element <b>26</b>. In this regard, cavity <b>159</b><i>a </i>includes a cavity flange portion <b>160</b><i>a </i>and a cavity skirt portion <b>161</b><i>a </i>that generally and respectively correspond to closure flange <b>23</b><i>a </i>(or <b>23</b><i>b</i>) and skirt <b>24</b>. Core surface <b>153</b> in the cavity skirt portion <b>161</b><i>a </i>corresponds to skirt interior surface <b>28</b>.

0061To fill cavity <b>159</b><i>a</i>, a material, such as a conventional thermoplastic material, is injected by conventional means through sprue <b>164</b> and gate <b>48</b> into cavity <b>159</b><i>a</i>, as will be understood by persons familiar with injection molding processes. <figref idref="DRAWINGS">FIG. 9</figref> illustrates cavity <b>159</b><i>a </i>in its filled state to produce a portion of closure <b>10</b><i>c </i>(that is, the portion of closure <b>10</b><i>c </i>other than deformable element <b>26</b>), which will be referred to by reference numeral <b>159</b><i>a′. </i>

0062According to another aspect of the present invention, deformable element <b>26</b> may be injection molded in a second stage or step of the injection molding process, subsequent to the injection of material into cavity <b>159</b><i>a </i>to produce portion <b>159</b><i>a</i>′. As shown in <figref idref="DRAWINGS">FIG. 10</figref>, a system <b>11</b><i>a</i>′ is provided for performing molding subsequent to the molding discussed above with respect to system <b>11</b><i>a</i>. The closure portion <b>159</b><i>a</i>′ may be transferred from the stage shown in <figref idref="DRAWINGS">FIG. 9</figref> to the stage shown in <figref idref="DRAWINGS">FIG. 10</figref> by robotic or automatic means, or, alternatively, the mold elements may be automatically moved so as to form the cavity <b>169</b><i>a</i>. Methods and systems for such transferring will be understood by persons familiar with such molding and actuation technology.

0063System <b>11</b><i>a</i>′ includes a cavity block <b>150</b><i>a</i>′ (the reference numeral includes a prime designation to indicate that the cavity block is in position for the subsequent molding step relating to deformable element <b>26</b>), an inner core <b>172</b>, a runner ejector <b>173</b>, a core bushing <b>174</b>, and a sleeve ejector <b>175</b>. The runner system includes runner channel <b>176</b>. The closure portion <b>159</b><i>a</i>′ from the injection molding step described above is disposed within system <b>11</b><i>a</i>′. A deformable element cavity <b>169</b><i>a </i>is formed by a portion of skirt interior surface <b>28</b>, which is formed on closure portion <b>159</b><i>a</i>′, and surfaces of retaining member <b>8</b>, inner core <b>172</b>, and a portion of ejector sleeve <b>175</b>.

0064To fill cavity <b>169</b><i>a</i>, material, such as the preferred TPE material described herein, is injected through channel <b>176</b> and into cavity <b>169</b><i>a</i>. <figref idref="DRAWINGS">FIG. 11</figref> illustrates cavity <b>169</b><i>a </i>in its filled state. The cross-hatching indicates the material of deformable element <b>26</b>, as described herein. Upon the completion of injection of such material into cavity <b>169</b><i>a</i>, and after separation of the runner and removal of the injection molded object from the mold <b>150</b><i>a</i>′, closure <b>10</b><i>c </i>may be ready for installing onto container <b>12</b> as described above.

0065The present invention is not limited to the particular configuration of the molding elements described herein, but rather encompasses any configuration that is capable of forming suitable cavities therein. Further, any runner systems may be employed, including commercially available cold runners or hot runners.

0066According to yet another aspect of the present invention, as illustrated in <figref idref="DRAWINGS">FIG. 12</figref>, a molding system <b>11</b><i>b </i>includes a molding cavity block <b>150</b><i>b</i>, a molding core <b>152</b>, a stripper <b>154</b>, an ejector <b>156</b>, and a pin <b>110</b>. Cavity block <b>150</b><i>b </i>defines a sprue <b>164</b> therethrough, as partially shown in <figref idref="DRAWINGS">FIG. 12</figref>. Cavity <b>150</b><i>b </i>defines a cavity block surface <b>151</b>, core <b>152</b> defines a mold surface <b>153</b>, and stripper <b>154</b> defines a surface <b>155</b> such that surfaces <b>151</b>, <b>153</b>, and <b>155</b> define a cavity <b>159</b><i>b</i>. Cavity <b>159</b><i>b </i>includes a cavityflange portion <b>160</b><i>b </i>and a cavity skirt portion <b>161</b><i>b</i>. Core surface <b>153</b> in the cavity skirt portion <b>161</b><i>b </i>corresponds (that is, in this case provides a surface for forming) skirt interior surface <b>28</b>.

0067Pin <b>110</b> extends through cavity surface <b>151</b> and into cavity <b>159</b><i>b</i>. Preferably, pin <b>110</b> is in contact with mold surface <b>153</b> at cavity skirt portion <b>161</b><i>b</i>, and specifically in the region thereof in which annular member <b>26</b> is to be formed. <figref idref="DRAWINGS">FIG. 12</figref> illustrates system <b>11</b><i>b </i>with cavity <b>159</b><i>b </i>already in its injected molded state, such that a portion <b>159</b><i>b</i>′ of the closure is shown. The present invention contemplates other configurations, such as for example a pin or pins extending through cavity <b>159</b><i>b </i>and through mold surface <b>153</b> into core <b>152</b>. Pin <b>110</b> may be of any configuration, such as for example any cross section or shape, disposed through any part of the closure in any configuration, and the like variations.

0068To fill cavity <b>159</b><i>b</i>, a material, such as a the thermoplastic material described herein, is injected into sprue <b>164</b> and gate <b>48</b> into cavity <b>159</b><i>b</i>. Because pin <b>110</b> extends into or through cavity <b>159</b><i>b</i>, the removal of pin <b>110</b> subsequent to the injection molding forms passage <b>7</b> within the injection molded material <b>159</b>′. Because the end of pin <b>110</b> is in contact with the core surface <b>153</b> during the injection stage, passage <b>7</b> is formed from the exterior surface of the closure portion <b>159</b><i>b</i>′ to the interior portion of closure portion <b>159</b><i>b</i>′ such that passage <b>7</b> enables the second material to flow from block <b>150</b><i>a </i>through closure portion <b>159</b><i>b</i>′ to inner surface <b>28</b> thereof. Thus, passage <b>7</b> extends through a portion of the formed flange <b>23</b> and skirt <b>24</b>, through which a second thermoplastic material may be injected to form the deformable element <b>26</b>. <figref idref="DRAWINGS">FIG. 5A</figref> also shows passage <b>7</b>.

0069According to another aspect of the present invention, deformable element <b>26</b> may be injection molded in the second stage or step of the injection molding process, by employing a passage, such as passage <b>7</b>, through a closure portion, such as portion <b>159</b><i>b</i>′. As shown in <figref idref="DRAWINGS">FIG. 13</figref>, a system <b>11</b><i>b</i>′ is provided for performing molding subsequent to the molding discussed above with respect to system <b>11</b><i>b </i>and closure portion <b>159</b><i>b</i>′. System <b>11</b><i>b</i>′ includes a cavity <b>150</b><i>b</i>′ (which includes a prime designation to indicate that it is in position for the subsequent molding step relating to deformable element <b>26</b>), an inner core <b>172</b>, a core bushing <b>174</b>, and a sleeve ejector <b>175</b> so as to enable the subsequent injection stage. A sprue <b>177</b> is formed in cavity <b>150</b><i>b</i>′. A deformable element cavity <b>169</b><i>b </i>is formed by a portion of the formed skirt interior surface <b>28</b>, which is formed on closure portion <b>159</b>′, and a surface of retaining member <b>8</b>, inner core <b>172</b>, and a portion of ejector sleeve <b>175</b>. <figref idref="DRAWINGS">FIG. 13</figref> shows cavity <b>169</b><i>b </i>in its filed state so as to illustrate portion <b>169</b><i>b.′</i>

0070To fill cavity <b>169</b><i>b</i>, material, such as the preferred material described herein, is injected through sprue <b>177</b> and into cavity <b>169</b><i>b</i>. Sprue <b>177</b> may be positioned at or near an end of passage <b>7</b> (which is shown in <figref idref="DRAWINGS">FIG. 13</figref> already having injection molded material disposed therein). Material may be injection molded through sprue <b>177</b>, through passage <b>7</b>, and into a cavity <b>169</b><i>b</i>, thereby forming deformable element <b>26</b>.

0071The terms “first” and “second” are employed to refer to the equipment, such as the molds, and the processing steps for convenience. The denoted sequence, however, refers to a preferred sequence. The present invention, however, is not limited to the order denoted by the numeric sequence, but rather encompasses any order of the steps, as will be clear to persons familiar to the technology relating to the process steps and equipment to which the numeric sequence refers.

0072The scope of the present invention should not be construed as limited to the detailed description of the embodiments described herein. Rather, the present invention encompasses numerous variations on the configurations and steps disclosed herein, as will be understood by persons familiar with the relevant prior art in light of the present disclosure. Such modifications should be considered within the spirit and scope of the appended claims.

0073<tables id="TABLE-US-00001" num="00001"><table frame="none" colsep="0" rowsep="0" pgwide="1"><tgroup align="left" colsep="0" rowsep="0" cols="9"><colspec colname="1" colwidth="28pt" align="left" /><colspec colname="2" colwidth="56pt" align="left" /><colspec colname="3" colwidth="35pt" align="left" /><colspec colname="4" colwidth="49pt" align="left" /><colspec colname="5" colwidth="28pt" align="center" /><colspec colname="6" colwidth="35pt" align="center" /><colspec colname="7" colwidth="35pt" align="center" /><colspec colname="8" colwidth="35pt" align="center" /><colspec colname="9" colwidth="35pt" align="center" /><thead><row><entry namest="1" nameend="9" rowsep="1">TABLE 1</entry></row><row><entry namest="1" nameend="9" align="center" rowsep="1" /></row><row><entry /><entry /><entry /><entry /><entry /><entry>Tensile</entry><entry>Flexural</entry><entry>Hardness</entry><entry>Hardness</entry></row><row><entry>Type</entry><entry>Material</entry><entry>Supplier</entry><entry>Grade</entry><entry>Density</entry><entry>Modulus</entry><entry>Modulus</entry><entry>Shore A</entry><entry>Shore D</entry></row><row><entry namest="1" nameend="9" align="center" rowsep="1" /></row></thead><tbody valign="top"><row><entry /></row></tbody></tgroup><tgroup align="left" colsep="0" rowsep="0" cols="9"><colspec colname="1" colwidth="28pt" align="left" /><colspec colname="2" colwidth="56pt" align="left" /><colspec colname="3" colwidth="35pt" align="left" /><colspec colname="4" colwidth="49pt" align="left" /><colspec colname="5" colwidth="28pt" align="char" char="." /><colspec colname="6" colwidth="35pt" align="center" /><colspec colname="7" colwidth="35pt" align="char" char="." /><colspec colname="8" colwidth="35pt" align="center" /><colspec colname="9" colwidth="35pt" align="center" /><tbody valign="top"><row><entry>TPE</entry><entry>Soft PP</entry><entry>Montell</entry><entry>Adflex 7149</entry><entry>0.89</entry><entry /><entry>500</entry><entry /><entry /></row><row><entry /><entry /><entry /><entry>XEP</entry></row><row><entry>TPE</entry><entry>SEBS</entry><entry>Evode</entry><entry>Evoprene 977</entry><entry>1.12</entry><entry /><entry /><entry>88</entry><entry>37</entry></row><row><entry>TPE</entry><entry>PP/EPDM</entry><entry>AES</entry><entry>Santoprene</entry><entry>0.97</entry><entry /><entry>103</entry><entry>87</entry></row><row><entry /><entry /><entry /><entry>271/87</entry></row><row><entry>PP</entry><entry>PP Block</entry><entry>Amoco</entry><entry>510 GA 20</entry><entry>0.9</entry><entry /><entry>900</entry></row><row><entry /><entry>Copolymer</entry></row><row><entry>PP</entry><entry>PP Random</entry><entry>BASF</entry><entry>Novolen</entry><entry>0.9</entry><entry>700</entry></row><row><entry /><entry>Copolymer</entry><entry /><entry>3300MC</entry></row><row><entry>Blend</entry><entry>PE/PA6 Blend</entry><entry>Elf</entry><entry>Orgalloy</entry><entry>1.01</entry><entry /><entry>750</entry><entry /><entry>65</entry></row><row><entry /><entry /><entry>Atochem</entry><entry>LE60LM</entry></row><row><entry>PP</entry><entry>PP Homopolymer</entry><entry>Rexene</entry><entry>Rexflex W109</entry><entry /><entry>380</entry><entry /><entry /><entry>63</entry></row><row><entry>Blend</entry><entry>Soft PP/PP Block</entry><entry>Montell/</entry><entry>Adflex/</entry><entry>0.9</entry><entry /><entry>700</entry></row><row><entry>(50/50)</entry><entry>Copolymer (see</entry><entry>Amoco</entry><entry>510 GA 20</entry></row><row><entry /><entry>above)</entry></row><row><entry>TPE</entry><entry>Butyl Rubber</entry><entry>AES</entry><entry>Trefsin</entry><entry>0.97</entry><entry /><entry>36</entry><entry>69</entry></row><row><entry /><entry /><entry /><entry>(3271-65w)</entry></row><row><entry namest="1" nameend="9" align="center" rowsep="1" /></row></tbody></tgroup></table></tables>